Method for making stator of rotary electrical machine

Patent metadata

Field	Value
Publication number	US-11075551-B2
Application number	US-201916518074-A
Country	US
Kind code	B2
Filing date	Jul 22, 2019
Priority date	Nov 9, 2015
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

A stator of a rotary electrical machine has a stator body formed by a stack of metal sheets. The stator body is delimited by inner and outer radial surfaces. Notches in the stator body extend axially. Each notch has a notch base and a notch opening, and the notch opening is on the side of the inner radial surface. A stator winding is supported by the stator body, and the winding has a plurality of winding parts. Each part is accommodated in one of the notches. Each of the notches at the notch opening has a closure element. Each winding par in a notch is retained between the notch base and the closure element. The closure elements are formed by offsetting at least one of the metal sheets of an adjacent notch in the direction of the notch.

First claim

The invention claimed is:

1. A method for making a stator ( 6 ) of a rotary electrical machine ( 1 ), comprising the steps of:
forming a stator body ( 4 ) from a stack of geometrically identical metal sheets, the stator body ( 4 ) having an axis (X) and provided with notches ( 44 , 41 , 42 , 43 ) extending both radially and axially and separated by teeth ( 45 ), the stator body ( 4 ) delimited by an inner radial surface and an outer radial surface, each of the notches ( 44 , 41 , 42 , 43 ) having a notch base ( 48 ) and a notch opening ( 49 ), the notch opening ( 49 ) being situated on a side of the inner radial surface of the stator body ( 4 );
providing a stator winding ( 5 ) comprising a plurality of winding parts ( 51 , 52 , 53 );
mounting the stator winding ( 5 ) to the stator body ( 4 ) so that each of the winding parts ( 51 , 52 , 53 ) is accommodated in one of the notches; and
forming at least one notch closure element ( 451 , 452 a , 452 b , 453 , 454 ) of each of the notches ( 44 , 41 , 42 , 43 ) at the notch opening of each of the notches ( 44 , 41 , 42 , 43 ) by circumferential offsetting at least one but not all of the metal sheets at the notch opening of the other of the notches in an orthoradial direction, one of the notches being consecutive to other of the notches;
the at least one notch closure element retaining one of the winding parts in the one of the notches between the notch base and the at least one notch closure element
wherein the step of forming the at least one notch closure element of one of the notches is carried out by radial introduction of a tool ( 60 ) into the notch opening of the other of the notches,
wherein the one of the notches is consecutive to the other of the notches, and wherein the tool ( 60 ) has a spherical form.

2. The method according to claim 1 , wherein one notch out of each of two consecutive notches of the notches ( 44 , 41 , 42 , 43 ) of the stator body ( 4 ) comprises a number N of the notch closure elements, wherein N is a whole number equal to 2 or more, and wherein another notch out of each of the two consecutive notches of the notches ( 44 , 41 , 42 , 43 ) of the stator body ( 4 ) comprises a number of the notch closure elements smaller than N.

3. The method according to claim 2 , wherein two of the notches with the number N of the notch closure elements are adjacent to both sides of the notch with the number of the notch closure elements smaller than N.

4. The method according to claim 3 , wherein with the notches being numbered according to a circumference of the stator, the notches with an even number comprise a number of the notch closure elements different from that of the notches with an odd number.

5. The method according to claim 3 , wherein the notch closure elements of the notches ( 42 ) are distributed axially along an axial length of the stator body.

6. The method according to claim 2 , wherein with the notches being numbered according to a circumference of the stator, the notches with an even number comprise a number of the notch closure elements different from that of the notches with an odd number.

7. The method according to claim 2 , wherein the notch closure elements of the notches ( 42 ) are distributed axially along an axial length of the stator body.

8. The method according to claim 1 , wherein with the notches being numbered according to a circumference of the stator, and wherein the notches with an even number comprise a number of the notch closure elements different from that of the notches with an odd number.

9. The method according to claim 8 , wherein the notch closure elements of the notches ( 42 ) are formed so as to be distributed axially along an axial length of the stator body.

10. The method according to claim 1 , wherein the notch closure elements of the notches ( 42 ) are formed so as to be distributed axially along an axial length of the stator body.

11. The method according to claim 10 , wherein at least one of the notch closure elements of one of the notches ( 41 , 43 ) with a smaller number of the notch closure elements is situated on a radial plane which passes via a middle of two adjacent notch closure elements of the notch ( 42 ) comprising the N notch closure elements.

12. The method according to claim 1 , wherein, for at least one notch ( 42 ) of the notches ( 44 , 41 , 42 , 43 ), with the at least one notch closure element of the at least one notch ( 42 ) situated respectively on first radial planes of the stator body, and the at least one notch closure element of the adjacent notch ( 41 , 43 ) being situated respectively on second radial planes of the stator body, the first radial planes are different from the second radial planes.

13. The method according to claim 12 , wherein the first radial planes and the second radial planes are spaced axially by a distance equal to at least two metal sheets.

14. The method according to claim 1 , wherein one of the notch closure elements ( 452 a ) is formed by deforming at least one of the metal sheets of one of the adjacent notches to the right in the orthogonal direction toward the notch, wherein another notch closure element ( 452 b ) is formed by deforming the at least one of the metal sheets of another adjacent notch to the left in the orthogonal direction toward the notch, and wherein the two notch closure elements ( 452 a , 452 b ) are formed so as to be situated in the same radial plane.

15. The method according to claim 1 , wherein the at least one notch closure element ( 451 , 452 , 453 , 454 ) is formed by deforming at least two contiguous metal sheets, such that the at least one notch closure element has an axial height of at least two metal sheets.

16. The method according to claim 1 , wherein one of the winding parts ( 51 , 52 , 53 ) of one of the notches comprises a plurality of wires aligned according to a column.

17. A method for making a stator ( 6 ) of a rotary electrical machine ( 1 ), comprising steps of:
forming a stator body ( 4 ) from a stack of geometrically identical metal sheets, the stator body ( 4 ) having an axis (X) and provided with notches ( 44 , 41 , 42 , 43 ) extending both radially and axially and separated by teeth ( 45 ), the stator body ( 4 ) delimited by an inner radial surface and an outer radial surface, each of the notches ( 44 , 41 , 42 , 43 ) having a notch base ( 48 ) and a notch opening ( 49 ), the notch opening ( 49 ) being situated on a side of the inner radial surface of the stator body ( 4 );
providing a stator winding ( 5 ) comprising a plurality of winding parts ( 51 , 52 , 53 );
mounting the stator winding ( 5 ) to the stator body ( 4 ) so that each of the winding parts ( 51 , 52 , 53 ) is accommodated in one of the notches; and
forming at least one notch closure element ( 451 , 452 a , 452 b , 453 , 454 ) of each of the notches ( 44 , 41 , 42 , 43 ) at the notch opening of each of the notches ( 44 , 41 , 42 , 43 ) by circumferential offsetting at least one but not all of the metal sheets at the notch opening of the other of the notches in an orthoradial direction, one of the notches being consecutive to other of the notches;
the at least one notch closure element retaining one of the winding parts in the one of the notches between the notch base and the at least one notch closure element;
the step of forming the at least one notch closure element of one of the notches is carried out by radial introduction of a tool ( 60 ) into the notch opening of the other of the notches, wherein the one of the notches is consec

Assignees

• Valeo Equip Electr Moteur

Inventors

• Bilteryst Pierre-Yves
• Delianne Henri
• Margueritte David
• Jozefowiez Eric
• Perreaut Sylvain
• Balthaze Patrice
• Battut Julien

Classifications

• H02K15/22

  Shaping or compacting conductors in slots or around salient poles (H02K15/28 takes precedence) · CPC title

• H02K15/13

  Applying slot closure means in the cores; Manufacture of slot closure means · CPC title

• H02K3/521

  applicable to stators only · CPC title

• H02K3/48 Primary

  in slots · CPC title

• H02K1/12 Primary

  Stationary parts of the magnetic circuit · CPC title